Battery powered surgical instrument

ABSTRACT

A powered endoscopic surgical apparatus is provided and includes a handle including a housing, a power source supported in the housing; an endoscopic portion extending distally from the housing of the handle; an end effector assembly coupled to a distal end of the endoscopic portion, the end effector assembly including a pair of jaws configured to perform a surgical function; a driving member; a drive source including a motor powered by the power source and connected to the driving member; and a gear assembly engaged with the motor. The gear assembly including a gear rack provided on the driving member; and a main gear operatively connected with the gear rack, the motor spinning the main gear such that rotary motion of the main gear moves the driving member in an axial direction such that the driving member actuates the end effector to perform the surgical function.

CROSS REFERENCE TO RELATED APPLICATIONS

This patent application is a Continuation application claiming thebenefit of and priority to U.S. patent application Ser. No. 15/606,052,filed May 26, 2017, which is a Continuation application claiming thebenefit of and priority to U.S. patent application Ser. No. 15/450,661,filed Mar. 6, 2017, (now U.S. Pat. No. 10,098,638), which is aContinuation application claiming the benefit of and priority to U.S.patent application Ser. No. 13/955,374, filed on Jul. 31, 2013, (nowU.S. Pat. No. 9,585,659) which is a Continuation application claimingthe benefit of and priority to U.S. patent application Ser. No.13/442,141, filed on Apr. 9, 2012 (now U.S. Pat. No. 8,505,799), whichis a Continuation application claiming the benefit of and priority toU.S. patent application Ser. No. 13/052,871, filed on Mar. 21, 2011 (nowU.S. Pat. No. 8,348,125), which is a Continuation application claimingthe benefit of and priority to U.S. patent application Ser. No.12/247,733, filed on Oct. 8, 2008 (now U.S. Pat. No. 7,909,221), whichis a Continuation application claiming the benefit of and priority toU.S. patent application Ser. No. 11/446,283, filed on Jun. 2, 2006 (nowU.S. Pat. No. 7,461,767), which claims the benefit of and priority toU.S. Provisional Patent Application Ser. No. 60/687,406 to Viola, etal., filed on Jun. 3, 2005 which is herein incorporated by reference inits entirety.

U.S. patent application Ser. No. 11/446,283, filed on Jun. 2, 2006 (nowU.S. Pat. No. 7,461,767) also claims the benefit of and priority to U.S.Provisional Patent Application Ser. No. 60/687,244 to Viola, et al.,filed on Jun. 3, 2005, which is also herein incorporated by reference inits entirety.

U.S. patent application Ser. No. 11/446,283, filed on Jun. 2, 2006 (nowU.S. Pat. No. 7,461,767), also relates to U.S. patent application Ser.No. 11/446,282, filed on Jun. 2, 2006 (now U.S. Pat. No. 7,464,847),which is herein incorporated by reference in its entirety.

BACKGROUND 1. Technical Field

The present disclosure relates to surgical instruments. Moreparticularly, the present disclosure relates to a surgical staplingdevice that has an improved and internally powered driving mechanism.

2. Background of the Related Art

Surgeons have recognized in the art the benefits of a compact surgicalapparatus for the application of surgical clips and staples to bodytissue in a number of different medical procedures. Often, prior artsurgical staplers require some degree of physical force or lateralmovement in order to operate a handle to actuate the surgical staplerand fire the staple after a compression to actuate the surgical staplerand fire the staple after a compression of tissue is made. It would bedesirable to have a precise surgical stapler device that is compact andeasy to use and will quickly and easily fire. Also, once compression ofthe desired stapling location is made, only a very limited degree offorce to the surgical stapling device should be required in order tocomplete the actuation of the device and thus firing of the staples suchas by actuating a trigger switch. Moreover, such a powered staplingdevice should be very easy to manipulate and hold by the surgeon.

Attempts have been made in the art to provide such a surgical staplingdevice that is pneumatic or gas powered and/or also externally poweredin order to remedy this desire. However, it would be beneficial toprovide a disposable apparatus for the application of staples to bodytissue that is self contained, self powered and easy to manufacture.

Additionally, tissue exhibits visco-elastic properties. Once underpressure from a jawed structure such as an approximation device of asurgical stapler, the body tissue will slowly compress. Blood and otherfluid traverses from the high pressure or gripped area to another lowpressure or adjacent area. Once released, as expected the fluid willreturn from the adjacent area to the previously compressed area.

Prior art surgical stapling devices will approximate tissue. Then, oncethe approximation is made, the surgeon will introduce the staple intothe body tissue.

It is desirable to provide a surgical stapler device that result in auniform staple formation. It is also desirable to provide a surgicalstapler device that allows for an appropriate time interval to elapsefor tissue compression. This allows for the blood and fluid to travelaway from the compressed area. Compression by an approximation devicereduces the amount of blood and fluid therebetween. Without suchcompression, an uncompressed body tissue remains thicker whereas thecompressed body tissue would be thinner, and more compact. The surgeonmust control compression time by observing the tissue or by using aseparate timing device.

Accordingly, compression of the tissue for the proper amount of time isimportant for a proper and uniform staple formation due to thisviscoelastic tissue phenomenon.

SUMMARY

According to a first aspect of the present disclosure, there is provideda surgical stapler. The stapler has a handle assembly including astationary handle and a trigger. The trigger is configured to manipulatea cam member through an actuating stroke. The stapler has an elongatedbody extending distally from the handle assembly and defining alongitudinal axis with a staple cartridge supported adjacent the distalend of the elongated body and containing a plurality of staples. Thestapler has an anvil pivotally mounted in relation to the cartridgeadjacent the distal end of the elongated body. The anvil has a fastenerforming surface thereon and is mounted for pivotal movement in relationto the cartridge between an open position having a distal end spacedfrom the staple cartridge and a closed position in close cooperativealignment with the staple cartridge. The stapler has an actuation sledsupported within the cartridge. The actuation sled is movable to urgethe plurality of staples from the cartridge. The stapler also has adrive assembly with a body having a working end and a cam membersupported on the working end. The cam member is positioned to translaterelative to the anvil to maintain the anvil in the closed positionduring firing of the stapler.

The trigger is operatively connected to a power cell. The power cell isoperably connected to a motor of the drive assembly. The manipulation ofthe trigger actuates the power cell such that the power cell powers thedrive assembly to effect translation of the cam member relative to theanvil. The stapler also has a channel for supporting the staplecartridge and the motor of the drive assembly controls the actuationsled supported within the cartridge. The actuation sled urges theplurality of staples from the cartridge when the anvil is in the closedposition and in cooperative alignment with the staple cartridge.

According to another aspect of the present disclosure, there is provideda surgical stapler. The stapler has a handle assembly with a stationaryhandle and a trigger configured to manipulate a cam member through anactuating stroke. The stapler also has an elongated body extendingdistally from the handle assembly and defining a longitudinal axis. Thestapler also has a staple cartridge supported adjacent the distal end ofthe elongated body and containing a plurality of staples with an anvilpivotally mounted in relation to the cartridge adjacent the distal endof the elongated body. The anvil has a fastener forming surface thereonand is mounted for pivotal movement in relation to the cartridge betweenan open position having a distal end spaced from the staple cartridgeand a closed position in close cooperative alignment with the staplecartridge.

The stapler has an actuation sled supported within the cartridge. Theactuation sled moves to urge the plurality of staples from thecartridge. The actuation sled is connected to a drive rack. The driveassembly has a body with a working end and a cam member supported on theworking end. The cam member is positioned to translate relative to theanvil to maintain the anvil in the closed position during firing of thestapler.

The trigger is operatively connected to a power cell. The power cell isoperably connected to a motor of the drive assembly such thatmanipulation of the trigger actuates the power cell such that the powercell powers the drive assembly to effect translation of the cam memberrelative to the anvil. The stapler also has a channel for supporting thestaple cartridge. The motor of the drive assembly controls the actuationsled supported within the cartridge. The actuation sled urges theplurality of staples from the cartridge when the anvil is in the closedposition and in cooperative alignment with the staple cartridge.

The stapler also has a protective casing. The protecting casing housesthe power cell and the motor in the protective casing and is connectedto the stationary handle. The motor has a motor drive shaft that extendsthrough the stationary handle to connect with the drive rack.

According to another aspect of the present disclosure, the surgicalstapler is powered by an inexpensive disposable power source that may beactuated by a manual or automatic switch or switch system and that has apower cell coupled to a motor assembly to assist with actuation andfiring of the staples.

In another embodiment, the stapler has a power supply that can actuatethe stapler and the power source can easily move the drive mechanism toan appropriate position for the next stapling operation.

According to another aspect of the present disclosure, there is provideda surgical stapler. The stapler has a handle assembly including atrigger and a clamping device including a staple cartridge with aplurality of staples and an anvil having a fastener forming surfacethereon. The stapler also has a controller configured to determine anoccurrence of clamping by the anvil and the staple cartridge. Thecontroller controls firing of the plurality of staples from the staplecartridge. When the trigger is actuated the controller delays firing ofthe plurality of staples from the staple cartridge to provide for apredetermined time period of tissue compression of the tissue betweenthe anvil and staple cartridge. The controller outputs a control signalto allow firing once the predetermined time period is reached. Thestapler also has a motor having a geared assembly. The motor is disposedin the handle and configured to receive the control signal from thecontroller. The motor is operatively connected to the staple cartridgeto fire the staples from the staple cartridge once the control signal isreceived.

It would additionally be advantageous to provide a surgical staplerhaving a timer device or display that would allow the surgeon to easilydetermine an appropriate compression time interval. It would be furtheradvantageous to provide a surgical stapler with a mechanical digital oranalog display to allow the surgeon to decide the optimal compressiontime, then actuate the stapler, insuring more uniformly shaped staples.It would still be further advantageous to provide a surgical staplerwith an automatic delay mechanism that, once the trigger is actuated,would fire the stapler after the predetermined amount of time elapses toallow for the required tissue compression. It would still be furtheradvantageous to provide a surgical stapler with a controller thatmeasures one or more parameters (i.e. thickness) of the tissue orstapler to provide the necessary tissue compression with the parametersbeing selected from the group consisting of motor speed, a gearreduction, or motor actuation time, motor rotation or other mechanicalmember travel distance and any combinations thereof.

According to a first aspect of the present disclosure, the surgicalstapler that has a motor that drives a firing mechanism component ofvarious mechanical components that will manipulate an actuator at acomplementary speed to ensure tissue compression and provide for auniform staple formation.

According to another aspect of the present disclosure, the surgicalstapler has a controller to place a delay between actuation of thefiring mechanism component and actual firing of the staple.

According to another aspect of the present disclosure, the surgicalstapler has a control device that controls a stroke parameter, adistance parameter and/or a time parameter of a firing mechanismcomponent to increase a tissue compression time of the approximationdevice.

According to still another aspect of the present disclosure, thesurgical stapler has a motor and a first switch. The first switch isconnected to a motor and delays the motor from actuating in order toachieve an amount of tissue compression by an approximation device. Thesurgical stapler may have a second switch. The second switch sensesanother location of a drive screw and actuates a reverse function of themotor to return the drive screw to an initial position.

According to still yet another aspect of the present disclosure, thesurgical stapler has an indicator that measure a distance traveled ofthe drive screw or a tissue compression time of the approximationdevice.

According to still another aspect of the present disclosure, thesurgical stapler has a visual indicator that indicates a position of thefiring mechanism component or indicates a status condition of thesurgical stapling.

According to a further aspect of the present disclosure, a poweredendoscopic surgical apparatus is provided. The surgical apparatusincludes a handle including a housing, a power source supported in thehousing; an endoscopic portion extending distally from the housing ofthe handle; a fastening assembly coupled to a distal end of theendoscopic portion, the fastening assembly including a pair of jawsdefining a stapling mechanism, at least one of the jaws being movablewith respect to the other jaw; a firing member extending between thehandle and the fastening assembly; a drive source proximal of theendoscopic portion, the drive source including a motor powered by thepower source and connected to the firing member; and a gear assemblyengaged with the drive shaft of the motor, the gear assembly beingdisposed within the housing. The gear assembly includes a gear rackprovided on the firing member; and a main gear operatively connectedwith the gear rack of the firing member, the motor being adapted andconfigured to spin the main gear such that rotary motion of the maingear moves the firing member linearly in an axial direction such that adistal end of the firing member engages and actuates the staplingmechanism in the fastening assembly.

According to yet another embodiment of the present disclosure, a poweredendoscopic surgical apparatus is provided and includes a handleincluding a housing, a power source supported in the housing; anendoscopic portion extending distally from the housing of the handle; anend effector assembly coupled to a distal end of the endoscopic portion,the end effector assembly including a pair of jaws configured to performa surgical function, at least one of the jaws being movable with respectto the other jaw; a driving member extending between the handle and theend effector assembly; a drive source proximal of the endoscopicportion, the drive source including a motor powered by the power sourceand connected to the driving member; and a gear assembly engaged withthe drive shaft of the motor, the gear assembly being disposed withinthe housing. The gear assembly includes a gear rack provided on thedriving member; and a main gear operatively connected with the gear rackof the driving member, the motor being adapted and configured to spinthe main gear such that rotary motion of the main gear moves the drivingmember linearly in an axial direction such that a distal end of thedriving member actuates the end effector to perform the surgicalfunction.

The end effector may be a stapling mechanism and the surgical functionmay include a stapling function. In use, linear movement of the drivingmember may actuate the end effector to perform a fastening function.

The main gear may be a spur gear. The gear rack may be formed along abottom surface of the firing member.

The handle may further include a manually actuated closing leversupported on the housing; and a closure member having a proximal endoperatively connected to the closing lever and a distal end extendingthrough the endoscopic portion to the fastening assembly, wherein manualactuation of the lever imparts linear movement of the closure member inan axial direction such that the distal end of the closure memberengages and actuates the fastening assembly to open and close the pairof jaws.

The handle may further include a trigger supported on the housing,wherein the trigger is operatively connected to the power source, thepower source being operatively connected to the motor of the drivesource such that manipulation of the trigger actuates the power sourceto activate the motor and rotate the main gear to actuate the firingmember.

The endoscopic surgical apparatus may further include a controllerconfigured to control the motor, the controller delaying activation ofthe motor for a predetermined time period after actuation of the lever.

The predetermined time period may be suitable in length to allowcompression of the tissue for the predetermined time period and to allowtissue to settle from a first initial state into a second compressedstate when the pair of jaws are in a closed position.

The endoscopic surgical apparatus may further include a dampeningdevice, the controller configured to control the dampening device, thedampening device modulating the motor for the predetermined time periodto allow for compression of tissue when the pair of jaws are in a closedposition.

The controller may control the motor and may delay an actuation thereof,the delay permitting a predetermined compression time period when thepair of jaws are in a closed position.

The controller may slow an operation of the motor to provide for thedelay to compress the tissue.

The handle may include a switch supported on the housing, wherein thelever actuates the switch upon actuation thereof, wherein the switch,when actuated, outputs a signal to the controller to complete a suitabletimer circuit for a predetermined time interval.

In use, upon passage of the predetermined time interval, actuation ofthe motor may be permitted.

The power source may be a battery. The battery may be modular.

DESCRIPTION OF THE DRAWINGS

Other and further objects, advantages and features of the presentdisclosure will be understood by reference to the followingspecification in conjunction with the accompanying drawings, in whichlike reference characters denote like elements of structure and:

FIG. 1 is a perspective view of a first embodiment of a surgical staplerof the present disclosure;

FIG. 1 A is a schematic of the handle portion of the surgical stapler ofFIG. 1 showing the trigger switch and a power cell coupled to a motor;

FIG. 2 is an exterior cross sectional view of the surgical stapler alongline 2-2 of FIG. 1 with the surgical stapler having a drive compartmentthereon;

FIG. 3 is an interior cross sectional view of the surgical stapler beingopposite the compartment;

FIG. 3A is an exploded view of a channel of the surgical stapler of oneembodiment of the stapler;

FIG. 3B is an exploded view of the staple cartridge, anvil and the drivesled of FIG. 1;

FIG. 4 is another cross sectional view of another embodiment of thesurgical stapler of FIG. 1 having a drive source in the handle of thesurgical stapler;

FIG. 4A illustrates another cross sectional view of the surgical staplerof FIG. 1 having a bevel geared arrangement;

FIG. 5 is a cross sectional view of an endoscopic portion of thesurgical stapler of FIG. 4;

FIG. 6 is yet another cross sectional view of another embodiment of thesurgical stapler of FIG. 1 with the drive source being in the handle andgeared to the drive screw of the surgical stapler;

FIG. 7 is a perspective view of a further embodiment of a surgicalstapler of the present disclosure;

FIG. 8 is a block diagram of a number of components of the surgicalstapler of FIG. 7;

FIG. 9A is an exploded view of a channel of the surgical stapler of FIG.7;

FIG. 9B is an exploded view of the staple cartridge, anvil and the drivesled of FIG. 7;

FIG. 10 is a perspective view of another embodiment of a surgicalstapler of the present disclosure having a number of lights;

FIG. 11 is a perspective view of still another embodiment of a surgicalstapler with a linear display;

FIG. 12 is a perspective view of yet another embodiment of a surgicalstapler having a digital display;

FIG. 13 is a perspective view of still another embodiment of a surgicalstapler with an analog display;

FIG. 14 is a cross sectional view of the surgical stapler along line14-14 of FIG. 10;

FIG. 15 is another cross sectional view of still another embodiment of asurgical stapler of the present disclosure along line 14-14 of FIG. 10with the stapler having a first switch and a second switch;

FIG. 15A is another cross sectional view of another embodiment of thestapler of FIG. 15 having the first switch which engages a tab on thelever;

FIG. 15B is still another cross sectional view of yet another embodimentof the stapler of FIG. 15 having the first switch located distally onthe lever;

FIG. 16 is another perspective view of still another embodiment of asurgical stapler with an audible alarm;

FIG. 17 is still another perspective view of another embodiment of asurgical stapler having the display showing an image;

FIG. 18 is a cross sectional view of a travel path of a drive memberthrough an endoscopic portion of a surgical stapler with a resistorstrip; and

FIG. 19 is a graphical representation of another embodiment of asurgical stapler having a non-contact sensor.

DETAILED DESCRIPTION

In the drawings and in the description which follows, the term“proximal”, as is traditional, will refer to the end of the apparatuswhich is closest to the operator, while the term “distal” will refer tothe end of the apparatus which is furthest from the operator.

The present disclosure shall be discussed in terms of both conventionaland endoscopic procedures and apparatus. However, use herein of termssuch as “endoscopic”, “endoscopically”, and “endoscopic portion”, amongothers, should not be construed to limit the present disclosure to anapparatus for use only in conjunction with an endoscopic tube. To thecontrary, it is believed that the apparatus of present disclosure mayfind use in procedures in these and other uses including but not limitedto where access is limited to a small incision such as arthroscopicand/or laparoscopic procedures, or any other conventional medicalprocedures known in the art.

The present disclosure may also be used with surgical stapling devicesthat do not have any separate clamping and firing procedures and may beused with such surgical stapling devices having a simultaneous clampingand firing. The present disclosure is also intended to be used with suchsurgical stapling devices have a discrete clamping gradient.

Referring now to the figures, wherein like reference numerals identifysimilar structural elements of the subject disclosure, there isillustrated in FIG. 1 a self-contained powered surgical staplerconstructed in accordance with one embodiment of the subject disclosureand designated generally by reference numeral 10. The surgical stapler10 is a disposable surgical instrument. However, the disposablearrangement is non-limiting and other non-disposable arrangements may becontemplated and are within the scope of the present disclosure.

The surgical stapler 10 of the present disclosure shown in a perspectiveview in FIG. 1 and described herein includes a frame generallyrepresented by reference numeral 12 and handle generally represented byreference numeral 14. The frame 12 defines a series of internal chambersor spaces for supporting various mechanical components of the surgicalstapler 10 as well as a number of staples therein for the application tothe body tissue.

The frame 12 supports an endoscopic portion 16 or an extended tube-likeportion. The endoscopic portion 16 is capable of being rotated and has arelatively narrow diameter, on the order of in a range that includesabout 10 millimeters, and is for insertion into a small opening in ortube inserted into the body, such as in the abdominal cavity, or othersimilar body cavities. The endoscopic portion 16 has a longitudinal axisand has a length. The length is appropriate for reaching the operationsite in the interior of the body. The surgical stapler 10 may be used inconjunction with other instruments such as endoscopes or other suchoptical devices for visually examining the interior of the body, forexample, cameras by means of fiber optics or other optical or recordingdevices.

Generally, the endoscopic portion 16 of the surgical stapler 10 isinserted through the small opening or wound, and is manipulated to theoperation site. At the operation site, the surgical stapler 10 isactuated.

The endoscopic portion 16 has a fastening assembly 18 and cuttingassembly that is known in the art. The fastening assembly 18 and thecutting assembly are located in a housing 20 which carries a fastenerand a cutter to the operation site. The fastening assembly 18 in thisone non-limiting embodiment has a pair of jaws 21, 22, or an anvil 22and a staple cartridge 21. The jaws 21, 22 may be a first jaw 21 andsecond jaw 22 that opens and closes or alternatively another clampingstructure for compression of the tissue at the stapling site. The jaws21,22 are defined by a staple carrying cartridge 21 and the anvil 22that is located therein. The staple carrying cartridge 21 is in oneembodiment located at the distal end of the housing 20. The staplecarrying cartridge 21 has one or a number of rows of staples. Thesurgical stapler 10 also has an anvil 22 with a forming surface (notshown) and further includes a knife (not shown) as is well known in theart for accomplishing the surgical stapling.

Generally, actuating the operating portion of the fastening assembly 18is accomplished via intermediate components disposed on or within thenarrow longitudinally extending tubular endoscopic portion 16. In oneembodiment, a cylindrical tubular sleeve member surrounds the endoscopicportion 16. The sleeve may be manipulated in a direction with thelongitudinal axis of the surgical stapling device. The surgical stapler10 of the present disclosure has three basic actions or functions.

First, the endoscopic portion 16 is introduced into the human or animalbody and is positioned with the jaws 21,22 aligned at the desiredstapling site to receive the target tissue. This may involve rotation ofthe endoscopic portion 16 relative to the body, either by rotating thesurgical stapler 10, as a whole, by rotating simply the endoscopicportion 16 relative to the frame 12 as permitted, or a combination ofboth actions. Thereafter, the surgical stapler 10 secures the targetbody tissue between the staple cartridge 21 in the distal portion of thehousing 20 and the anvil 22. This is accomplished by a clamping actionof the jaws 21, 22 or alternatively by another similar or differentclamping member. The jaws 21, 22 are allowed to remain in the closedposition for a period of time. The jaws 21, 22 remaining closed for apredetermined period of time allow any excess liquid or fluid in thetissues to drain out of the body tissues prior to actuation of thestapling mechanism. This ensures that the liquid does not rapidlytraverse out of the tissues to impede formation of the closed or formedstaple and ensures a proper staple formation.

With the target tissue clamped between the anvil 22 and the staplecartridge 21, a camming surface which surrounds the housing 20 and anvilmember 22 may be employed to close the jaws 21, 22 of the surgicalstapler 10 and clamp the tissue between the anvil 22 and the tissuecontacting surface of the staple cartridge 21. The jaws 21, 22 may beclamped by actuating or closing lever 24 that is opposite the jaws 21,22. Thereafter, the third action of the operator or more particularlythe surgeon is that of applying the staples to the body tissue. Alongitudinally extending channel is employed to deliver longitudinalmotion to an axial drive member and a tissue cutting knife.

The stapler 10 may have an axial drive member or an axial drive screw tocontact a pusher. The pusher elements drive the staples through the bodytissue against the fastener or forming surface of the anvil 22.Typically, in the art the surgical stapler 10 fires usually by anactuation of a first trigger 26. Thereafter, the clamping action of thejaws 21, 22 is released and the surgical stapler 10 or a portion thereofmay be withdrawn from the body cavity or site.

A known and recognized benefit is that often an operator will desire asurgical stapler 10 that is self-actuating or that actuates with only alimited degree of physical force using the trigger handle (not shown) orusing a trigger switch 26. It is envisioned that surgeons would desiresuch a surgical stapler 10 that does not have to be connected to anyexternal power supply but instead includes an internal battery operatedpower supply. Operators would desire a surgical stapler having aninternal power source that is comfortable to hold, compact and that isvery suitable for endoscopic or laparoscopic procedures as well as otherconventional surgical procedures. The stapler 10 of the presentdisclosure is advantageous since it is a compact and ergonomic member.It is also very advantageous to form such a surgical stapler 10 from fewcomponent parts relative to the prior art surgical instruments. Thisreduces manufacturing costs of the surgical stapler.

The present disclosure in one embodiment uses a motor drive sourcehaving a substantially offset or a direct drive to remedy these knownissues in the art. FIG. 1 A shows a schematic illustration of aninterior of the handle 14. The surgical stapler 10 in this embodiment ispowered by a motor 30. The trigger switch 26 in this embodiment isconnected by lead 27 to a power source 29 such to as a battery. Thebattery 29 is connected by lead 31 to a motor 30. The motor is connectedby lead 31 to the switch 26. Upon the actuation of switch 26, power willtraverse from the battery 29 to the motor 30. The energized motor 30will rotate the motor drive shaft 32 to spin gear 68. Gear 68 is incontact with gear 70. Gear 68 rotates second gear 70 which will rotatedrive screw 66. The drive screw 66 upon rotation will move in alongitudinal manner to actuate one or more other components of thesurgical stapler 10 such for compression of tissue or stapling.Although, the battery 29 and the motor 30 are shown as being located inthe handle 14, other locations are contemplated.

Referring now to FIG. 2, there is shown a cross sectional view of thesurgical stapler 10 of the present disclosure along line 2-2 of FIG. 1from a rear view of the surgical stapler of FIG. 1. Disposed on anadjacent side of the surgical stapler 10 is shown a protective housing28. The protective housing 28 is for housing one or more components ofthe surgical stapler 10. The protective housing 28 may be disposed oneither adjacent side of the handle 14 or in another position beingparallel with the handle. The protective housing 28 is a generally acylindrical compact member having an interior that is disposed adjacentto, and on a lateral side of the handle 14. The protective housing 28 ismade from a suitable thermoplastic member that is suitable for surgicalprocedures and has a suitable volume to hold one or more commerciallyavailable batteries, or another power source. Although shown ascylindrical, other shapes are possible and the protective housing 28 isnot limited to this configuration. The protective housing 28 has theinterior space. The space has a compact size and has an advantageousdrive source 30 disposed therein.

The surgical stapler 10 of the present disclosure may have a first axialdrive shaft for operation of the stapling mechanism in the proximal endof the surgical stapler 10 as is known in the art. Such staplingmechanisms are well known in the art and may be found in U.S. Pat. No.6,330,965 B1 to Milliman, et al., U.S. Pat. No. 6,250,532 B1 to Green,et al., U.S. Pat. No. 6,241,139 B1 to Milliman, et al., U.S. Pat. No.6,109,500 to Alli et al., U.S. Pat. No. 6,202,914 B1 to Geiste, et al.,U.S. Pat. No. 6,032,849 to Mastri, et al. and U.S. Pat. No. 5,954,259 toViola, et al., which are all herein incorporated by reference in theirentirety.

The drive source 30 has electrical contacts to an integrated powersupply and an optional switch system. The drive source 30 is run by anyintegrated power supply that is compact, and low cost to manufacture. Inone embodiment, the drive source 30 also has a suitable amount of torquein order to fire and apply the staple to the body tissue or bone, andform the staple using a forming surface disposed on an anvil. In oneembodiment, the drive source 30 is a simple motor assembly having adrive shaft 32. The motor may be any device that converts the currentfrom the portable power cells into mechanical energy but may be anymotor that is low cost and that may be disposable and easily discardedafter use. The drive shaft 32 is connected through the handle 14 througha sealed aperture in the handle 14. Aperture may be sealed using an “O”ring or similar structure to ensure no fluids enter the stapler 10.

Alternatively, the drive source 30 may comprise any electrically poweredmotor known in the art. The present disclosure provides that the drivesource 30 may have a number of modular components that are disposable,permanent, replaceable or interchangeable. In one aspect, the motor 30may be a modular component and replaceable. In another aspect, thebattery can be a modular component and replaceable separate from thedrive source 30. In still another aspect, both the battery and the motorof the drive source 30 may be modular components. The motor and batterymay be stored in a casing or be separate units.

In one embodiment, the drive source 30 has electrical contacts to, andis powered by, one more internal power cells. The power cells may be oneor more disposable or rechargeable power cells. For example, the powercells may be a nickel cadmium type battery, an alkaline battery, alithium battery, or a nickel metal hydride and may be replaceable ordisposable with the entire surgical stapler 10. Alternatively, the powercells of the drive source 30 may also 5 disengage from the surgicalstapler 10 for recharging. Once disconnected, the surgical stapler 10itself then may be discarded after use.

In one embodiment, the one or more power cells of the drive source 30are disposed and oriented in a generally perpendicular fashion relativeto an 10 outer surface of the handle 14 as shown in the housing 28 andoptionally may be located in a casing with the motor assembly. In thisnon-limiting embodiment, the surgical stapler 10 may have a discreteanalog switch assembly to actuate the drive source. The switch assemblymay be located in any location or on an external surface of the surgicalstapler 10, or be integral with the trigger switch 26. Alternatively,the drive source 30 may be actuated by a counter clockwise rotation ofthe protective housing 28 to actuate the drive source. Still further inanother embodiment, the drive source 30 may be actuated by the trigger26 or by simply the lowering an elevation of the lever 24.

Referring now to FIG. 3, there is shown an opposite lateral sidecross-sectional view of the surgical stapler 10 of FIG. 2, having thelever 24 in an elevated position or elevated and away from the handle14. The drive shaft 32 of the drive source 30 extends through thelateral side wall of the handle 14 and engages a gear assembly 34. Thegear assembly 34 may have any number of gears to transmit motion fromthe drive source 30 in protective housing 28 to another member to move asuitable driving member for stapling. The driving member is a gear rackor drive screw or other member to fire the staples in the staplecartridge 21. Various driving configuration are possible and the presentstapler 10 is not limited to any such particular driving arrangement. Inthis one non-limiting embodiment, the gear assembly 34 has a main gear36 and two subordinate gears 38, 40. The gear assembly 34 laterallyextends into the interior space of the handle 14 as shown. In oneembodiment, the gear 36 is a spur gear. In one embodiment, thesubordinate gears 38, 40 are a pair of pinion gears. In yet anotherembodiment, instead of a pair of pinion gears 38, 40, the stapler 10 mayhave one pinion gear. Various gearing configurations are possible andwithin the scope of the present disclosure.

The lever 24 as shown has a first lever side 42 that has a transverseaperture 44 being disposed therethrough. The lever 24 is connected to amember 46 by a link pin 48 through aperture 44 in the lever 24. Themember 46 moves laterally through the endoscopic portion 16. The member46 controls the jaws 21, 22 shown in FIG. 1 to open or close and for thesurgeon to clamp the jaws of the surgical stapler 10 on or at thedesired tissue site. The lever 24 also has an intermediate portion 50.The intermediate portion 50 has a second aperture 52 being disposed in abottom side of the lever 24. The lever 24 is further connected to asecond linkage assembly 54 through the second aperture 52 by a secondlink pin 56. It should be appreciated that the powered arrangement isnot limited to any such device that requires tissue approximation suchas a TA surgical stapler such as U.S. Pat. No. 6,817,508 to Racenet, etal. which is herein incorporated by reference in its entirety, and thepowered arrangement may encompass other staplers that do not require anysuch tissue approximation prior to firing.

In one embodiment, the second linkage assembly 54 has two discretelinks. Each of the links is spaced apart and is connected to one anotherto form an integral second linkage assembly 54. The second linkageassembly 54 is for translating a downward force from the lever 24 intoan axial lateral force and for moving one or more structures in thehandle 14. The second linkage assembly 54 is further fixedly connectedto an interior pin 58 of the handle 14. The lever 24 still further hasan orthogonal notch 60. The notch 60 is disposed on the lever 24 withthe notch being between the transverse aperture 44 and the secondaperture 52. The notch 60 provides clearance and prevents the lever 24from interfering or otherwise contacting the gear assembly 34 during afiring sequence or otherwise when the drive source 30 is actuated.

As shown in the raised position, the free end 62 of the lever 24 restselevated above the handle 14 as shown. As mentioned, when a staplingsite is determined by the operator, the operator will use the jaws 21,22 to compress the tissue at the stapling site to clamp the tissue for aperiod of time. The surgeon can control the jaws by lowering or closinglever 24 (from the elevated position to a position that rests on thehandle 14). Upon lowering the lever 24 from the elevated position abovethe handle 14, the lever 24 lowers the second linkage assembly 54.

The second linkage assembly 54 forces the lever 24 at the first side 42to move the member 46. The member 46 is then manipulated in a lateralaxial direction opposite the handle 14. Thus, member 46 drives the jaws21, 22 at the distal side of the surgical stapler 10 for clamping theselected body tissue between the jaws. In one embodiment, the member 46may further contact a lead, switch or mechanical member in order toprovide an audible or visual alert so as to inform thephysician/operator that a preset period of time has elapsed forcompression of tissue between the jaws and the firing can begin. Variousclamp arrangements are possible and the present arrangement is forillustration purposes as it is envisioned that the clamp may be poweredby the drive source 30, or by a separate drive source.

In another embodiment of the surgical stapler 10, the surgical stapler10 may be manually actuated for stapling. In the manual embodiment, whenthe desired stapling is desired, the operator will actuate either atrigger handle (not shown) or in another embodiment will actuate ahandle assembly having a linkage. Still in another embodiment, the lever24 may operate the switch assembly at an end of the lever 24. The switchassembly 26 may be on any location of the surgical stapler 10 or may beadjacent to the protective housing 28.

The surgical stapler 10 further has a firing member 64. The firingmember 64 is laterally disposed in the handle 14 and can optionallyassist with driving an axial drive screw or another driving member toactuate the stapling mechanism in the distal side of the surgicalstapler 10. The firing member 64 may include a single driving memberthat can control both the clamping and the firing of the surgicalstapler 10. In another embodiment, the firing member 64 canalternatively include separate driving members with one driving memberfor the firing of the stapler cartridge 21 and another driving memberfor closing the jaws 21, 22. Various configurations are possible andwithin the scope of the present disclosure. The firing member 64 is alongitudinal member having a bottom driving surface 65. However, thelongitudinal firing member 64 can be a single component or constructedof other multiple members. The firing member 64 is disposed in alongitudinal manner in the interior of the handle 14 of the surgicalstapler 10. Upon actuation, the motor in the housing 28 spins the maingear 36 that contacts or is connected to the bottom driving surface 65of the firing member 64. Gear 36 rotates in a counterclockwise fashion.Thus, in this manner, the drive source 30 will rotate the gear assembly34 that will move the firing member 64 in an axial direction toward thedistal direction of the surgical device 10 and away from the handle 14.A rotation of the main gear 36 applies a force to the firing member 64on the bottom driving surface 65 for the purpose of axially moving thefiring member in a longitudinal distal manner. This axial movement ofthe firing member 64 will impart an axial force the corresponding memberin the endoscopic potion 16 that will engage the stapling mechanism.

A beneficial aspect of the present disclosure is that the drive source30 will then allow a greater amount of torque to be applied to thedriving member 64 relative to a manually actuated apparatus without anymotor assembly 30. A significant aspect of the present disclosure isthat the drive source or motor 30 is a low cost device that may bediscarded. Given that the drive source 30 may be discarded, the drivesource or motor 30 may be connected to an optional analog or digitalcircuit on a controller to drive the firing member 64 with apredetermined amount of torque so that a considerable amount of power isreleased from the drive source 30 each instance the firing is desired.Moreover, the surgical stapler 10 provides that the firing member 64 isdirectly driven by the drive source 30, or geared by a number of gearsfor the purpose of actuating the stapling mechanism without undue forceor movement applied to the handle 14 or another trigger handle (notshown) of the surgical stapler 10. This is advantageous since thesurgeon can precisely locate the stapler 10 at a site and then fire thestapler 10.

FIG. 3A shows an exploded view of a number of components of the surgicalstapler 10 of FIG. 1. The stapler 10 has a rack 64 that is slidable inthe handle portion 14. The rack 64 interfaces with a clamp tube 102. Ona distal side of the clamp tube 102 is a channel 104. The channel 104engages with the clamp tube 102 and a pair of forks 106,108 on a distalside thereof. The stapler 10 also has an upper cover 110 and a lowercover 112, and an extension tube 114. The extension tube 114 engageswith a collar tube 116. The stapler 10 also has a rotation knob 118 witha channel portion 120. The channel portion 120 has a pair of cammingsurfaces 122 on a distal end. The distal end also has a crimp 124 in adistal side to receive the anvil 22.

In operation, the rack 64 slides and moves the clamp tube 102 distally.The clamp tube 102 is provided to interconnect the handle portion 14arid the extension tube 114. The channel 104 is slidably mounted forreciprocal longitudinal motion. The extension tube 114 provides supportfor the surgical stapler 10 and has slots that interface with the collartube 116. The surgical stapler 10 also has a support 120 forlongitudinal motion and to operate the stapling mechanism as describedin FIG. 2b . The operation of these components is well known and isdisclosed in U.S. Pat. No. 5,318,221 to Green, et al., which is hereinincorporated by reference in its entirety.

Advantageously, the rack 64 is driven distally to advance the channel104 in a distal manner. The channel 104 delivers longitudinal motion toa pusher cam bar or an axial drive member as is known in the art foroperation of the staple cartridge 21 shown in FIG. 2b . It should beappreciated that the components shown in FIG. 3A only illustrate oneembodiment of the present surgical stapler 10, and instead of the rack64, the surgical stapler 10 may have a drive screw (FIG. 4) forlongitudinal motion and in order to actuate the staple cartridge 21.Referring now to FIG. 3B, there is shown an exploded view of the anvil22 and the staple cartridge 132 having an actuation sled 169.

Referring to FIG. 2b , the staple cartridge 21 includes an anvilassembly 130 and a cartridge assembly 132 shown in an exploded view forillustration purposes. The anvil assembly 130 includes anvil portion 22having a plurality of staple deforming concavities (not shown) and acover plate 136 secured to a top 10 surface of anvil portion 134 todefine a cavity (not shown). The cover plate 136 prevents pinching oftissue during clamping and firing of the surgical stapler 10. The cavityis dimensioned to receive a distal end of an axial drive assembly 138.

The anvil 130 has a longitudinal slot 140 that extends through anvilportion 130 to facilitate passage of retention flange 142 of the axialdrive assembly 138 into the anvil slot 140. A camming surface 144 formedon anvil portion 22 is positioned to engage axial drive assembly 138 tofacilitate clamping of tissue. A pair of pivot members 146 formed onanvil portion 130 is positioned within slots 146′ formed in carrier 148to guide the anvil portion 130 between the open and 20 clampedpositions.

The stapler 10 has a pair of stabilizing members 152 engage a respectiveshoulder formed on carrier 148 to prevent anvil portion 130 from slidingaxially relative to staple cartridge 132 as camming surface of the anvil130 is deformed. Cartridge assembly 132 includes the carrier 148 whichdefines an elongated support channel 154. Elongated support channel 154is dimensioned and configured to receive the staple cartridge 132 whichis shown above the carrier 148 in the exploded view of FIG. 2b .Corresponding tabs and slots formed along staple cartridge 132 andelongated support channel 148′ function to retain staple cartridge 132within support channel 154 of carrier 148. A pair of support strutsformed on the staple cartridge 132 are positioned to rest on side wallsof carrier 148 to further stabilize staple cartridge 132 within supportchannel 154, however to other arrangements to support the cartridge 132on the channel 154 can be used and this arrangement is not limiting.

Staple cartridge 132 includes retention slots 156 for receiving aplurality of fasteners 158 and pushers 160. Longitudinal slots 156extend through staple cartridge 132 to accommodate upstanding cam wedges162 of the actuation sled 164. A central longitudinal slot 166 extendsalong the length of staple cartridge 132 to facilitate passage of aknife blade (not shown). During operation of surgical stapler 10,actuation sled 164 is drive distally to translate through longitudinalslot 156 of staple cartridge 132 and to advance cam wedges 162 distallyand into sequential contact with pushers 160, to cause pushers 160 totranslate vertically within slots 156 and urge fasteners 158 from slots156 into the staple deforming cavities of anvil assembly 130 to effectthe stapling of tissue.

Referring now to FIG. 4, there is shown another embodiment of thepresent disclosure. In this embodiment, the drive source 30 is disposedin an interior space of the handle 14 in a location to balance anoverall weight of the surgical stapler 10 for a more ergonomic,comfortable design. The surgical stapler 10, in this embodiment, has adrive screw 66 as a drive member in contrast to the rack 64 of FIG. 3A.The drive screw 66 is a threaded rod having a number of helical groovesthat are intended to rotate and contact another axial member shown aboveto actuate the stapling mechanism in the distal location of the surgicalstapler 10 once a tissue compression is made by the surgeon. Variousconfigurations are possible, and it should be appreciated that thestapler 10 of the present disclosure is not intended to be limited toany specific stapler mechanism.

In one embodiment, the drive source 30 is disposed and lies in alongitudinal plane in the handle 14. The drive source 30 is disposedsubstantially parallel to a longitudinal axis of the surgical stapler10. This location of the drive source 30 provides for a compact and selfpowered surgical stapler 10 that may be comfortably balanced andergonomically grasped by the surgeon. The drive source 30 has the driveshaft 32. Drive shaft 32 is connected to a first drive gear 68. Thefirst drive gear 68 has teeth that mesh with, and rotate a number ofteeth of a second translating gear 70 as shown.

The second translating gear 70 further has a bore or aperture in acenter of the second translating gear 70. The second translating gear 70further is connected to a collar 72 in a center of the secondtranslating gear. The collar 72 engages the drive screw 66 of thesurgical stapler 10. A clockwise rotation of the second translating gear70 will also rotate the collar 72 in a similar direction. The collar 72will then, upon rotation, cooperates and engage with the drive screw 66to move the drive screw 66 in a distal manner.

This rotation of the collar 72 allows the drive screw 66 to rotate andmove distally. The drive screw 66 rotates and moves in an axial mannerthrough the bore of the second translating gear 70 and the collar in adirection toward and through the endoscopic portion 16 of the surgicalstapler 10. Upon rotation, the drive screw 66 will traverse laterally byrotation into the endoscopic portion 16 a predetermined amount in adirection away from the handle 14 of the surgical stapler 10 to actuatethe stapler mechanism. A significant aspect of this embodiment is thatthe drive screw 66 has a considerable amount of torque from motor 30 inorder to translate the force to the staple mechanism and to form thestaples against anvil.

FIG. 4A illustrates another embodiment of the surgical stapler 10. Inthis embodiment, the motor 30 is shown unconnected from any power supplyfor illustration purposes. The motor 30 has a drive shaft 32. The driveshaft 32 is connected to a first bevel gear 31.

In this embodiment, the motor 30 is disposed at ninety degrees from thedrive screw 66. Upon the actuation of trigger switch 26 (FIG. 1) powerwill traverse from the battery 29 to the motor 30 (FIG. 1 A). Theenergized motor 30 will rotate the motor drive shaft 32 to spin bevelgear 31. Bevel gear 31 is in contact with second gear 33 that isdisposed in concentric fashion with drive screw 66 using member 72 asdiscussed above.

Bevel gear 31 will rotate drive screw 66 to move the drive screw 66 in alongitudinal manner to actuate one or more other components of thesurgical stapler 10 such for tissue compression or for stapling. Bevelgear 31 is useful to change a rotation direction of the motor outputshaft 32 to move drive screw 66 longitudinally or distally andproximally, and to orient the motor 30 in an advantageous mannerrelative to the handle 14. Bevel gear 31 has teeth that can be straight,spiral or hypoid. Although bevel gear 31 is shown as perpendicular togear 33, other arrangements are contemplated. Instead, of bevel gear 31with second gear 33 oriented as shown the surgical stapler 10 mayincorporate a hypoid gear which can engage with the axes in differentplanes. Hypoid gear may further permit different spacing arrangements ofthe motor 30 relative to the drive screw 66 to further provide for amore compact, balanced and ergonomic stapler design.

Referring now to FIG. 5, there is shown a cross sectional view of theendoscopic device 16. Upon actuation, the drive screw 66 rotates apredetermined distance through a central bore 74 in the endoscopicportion 16. After traversing the predetermined distance, the drive screw66 will contact a longitudinal firing member 76. The longitudinal firingmember 76 will then contact a complementary structure to fire thestaples in the staple cartridge 21 in the distal region of the surgicalstapler 10 as is known in the art. In another exemplary embodiment, ofthe present disclosure, the drive source 30 may be a reversible drivesource. Additionally, the staple cartridge 21 may have one row to ormultiple rows of staples and the surgical stapler 10 may fire with anamount of torque to easily form staples having the desiredconfiguration.

In this alternative embodiment, the drive screw 66 may reverseautomatically or manually to move proximally at the conclusion of thestapling relative to the endoscopic portion 16. Upon the drive source 30actuated by the switch 26 or another manual or automatic actuatingdevice, the drive source rotates the drive shaft 32 in the oppositerotational direction. The drive shaft 32 then rotates the first drivegear 68 in the opposite rotational direction. Thereafter, a number ofteeth of the first drive gear 66 rotate the second translating gear 70in the opposite direction. The second translating gear 70 will thenrotate the drive screw 66 in the opposite direction to return the drivescrew 68 to an initial position for the next stapling operation.

Referring now to FIG. 6, there is shown another alternative embodimentof the present disclosure. In this embodiment, the jaws 21, 22 arepowered by the drive source 30. The jaws 21, 22 may be moved in closealignment with one another to clamp tissue therebetween and be poweredby motor or drive source 30. The surgical stapler 10 has a drive source30 that has a drive gear 74 being connected to the output drive shaft(not shown) of the motor 30 or drive source. The drive gear 74 isdirectly connected to the drive source 30, however alternatively may beconnected to the drive source 30 by another gear or by another linkagedepending on the space constraints of the handle 14. The surgicalstapler 10 further has a second translation gear 76. The secondtranslation gear 76 also is connected through the drive screw 66 thatdrives the drive screw 66 to fire the staple cartridge 21 as discussedpreviously.

In this embodiment, the lever 24 is connected to the linkage assembly 54at the intermediate portion 50 of the lever 24. The lever 24 whenlowered from the elevated position, imparts a downward force on thelinkage assembly 54. Thereafter, the linkage assembly 54 fixed at oneend by the interior pin 58 rotates about the interior pin and moves thelever 24 in an axial manner. This moves and advances a linkage (notshown) for clamping the tissue. Still further, the member or anothercomponent may actuate a timer (not shown) or display to alert thephysician/operator to activate the trigger and to initiate the drivesource 30. In still another embodiment of the present disclosure, theclamping may be mechanically connected or linked to the drive source 30to provide for a powered compression of tissue. In still anotherembodiment, the clamping can be performed simultaneously with the firingof the trigger handle 26, and may be powered by the drive source 30 asopposed to independently of firing.

Once the actuation of the drive source 30 occurs, the drive source willturn the drive gear 74. The drive gear 74 will then directly rotate thesecond translation gear 76 and the drive screw 66 disposed directlythrough the bore of the second translation gear. Again, the drive screw66 will then impart the required axial force to discharge the staplesfrom the staple cartridge 21 in the distal location of the surgicalstapler 10. As mentioned, once the drive screw 66 travels apredetermined distance, the drive screw 66 will actuate thecorresponding stapler mechanism to fire the staples in the staplecartridge 21.

Referring now to FIG. 7, a self-contained powered surgical staplerconstructed in accordance with an embodiment of the subject disclosureis shown and designated generally by reference numeral 100. The surgicalstapler 100 is generally intended to be disposable, however thedisposable arrangement is non-limiting and other non-disposablearrangements may be contemplated and are within the scope of the presentdisclosure.

The surgical stapler 100 of the present disclosure (shown in aperspective view in FIG. 7 and described herein) includes a framegenerally represented by reference numeral 12 and handle generallyrepresented by reference numeral 14. The frame 12 defines a series ofinternal chambers or spaces for supporting various inter-cooperatingmechanical components of the surgical stapler 100 as well as a number ofstaples therein for the application to the body tissue.

The frame 12 supports a portion 16 or an extended tube-like portion. Theportion 16 is capable of being rotated and has a relatively narrowdiameter in a range of about 10 millimeters, and is for insertion into asmall opening or tube inserted into the body, such as in the abdominalcavity, or other similar body cavities. The portion 16 has alongitudinal axis and has a length appropriate for reaching theoperation site in the interior of the body. The surgical stapler 100 maybe used in conjunction with other instruments such as endoscopes orother such optical devices for visually examining the interior of thebody, for example, cameras by means of CCD devices, fiber optics orother optical or recording devices.

Generally, portion 16 of the surgical stapler 100 is inserted throughthe small opening or wound, and is manipulated to the operation site.The present disclosure is intended to be used with any surgical staplerincluding but not limited to surgical staplers having simultaneousclamping and independent clamping.

Portion 16 has a fastening assembly generally represented by referencenumber 18 and cutting assembly (not shown) that is known in the art. Thefastening assembly 18 and the cutting assembly (not shown) are locatedin a housing 20 which carries a fastener and an optional cutter to theoperation site. The fastening assembly 18 in this particular embodimenthas a jaw or a staple cartridge 21 and a second jaw or anvil 22. Thestaple cartridge 21 and the anvil 22 may be brought into closecooperative alignment with one another so the jaws 21, 22 form a clamptherebetween. The jaws 21, 22 may be a first and second jaw that openand close or may be another different clamping type structure as isknown in the art. The staple cartridge 21 may be located at the distalend of the housing 20, in the jaws 21, 22 themselves or may be locatedin other locations as described in U.S. Pat. No. 7,044,353 to Mastri, etal. which is herein incorporated by reference in its entirety. Thestaple cartridge 21 has one or a number of rows of staples. The surgicalstapler 100 also has an anvil (not shown) and further may include anoptional knife (not shown) as is well known in the art for accomplishingthe stapling. It is appreciated that the closing of the jaws 21, 22 withthe staple cartridge 21 and the anvil 22 may be accomplished by pivotingthe anvil 22 relative to the staple cartridge 21, or by pivoting thestaple cartridge 21 relative to the anvil 22, or by pivoting both thestaple cartridge 21 and the anvil 22 relative to one another.

Generally, actuating the operating portion of the fastening assembly 18is accomplished via intermediate components disposed on or within thenarrow longitudinally extending tubular portion 16. In one non-limitingembodiment, a cylindrical tubular sleeve member surrounds the portion16. The sleeve may be manipulated in a direction with the longitudinalaxis of the surgical stapling device. The sleeve slides onto the anvil22 for closing the jaws 21, 22 that are biased open by a biasing device(not shown) to accomplish the clamping. The surgical stapler 100 of thepresent disclosure has three basic actions or functions, however, thepresent disclosure is intended to be used with any surgical staplerincluding but not limited to surgical staplers having simultaneousclamping (i.e., clamping and firing the stapler at the same time) anddependent or independent clamping (i.e., clamping prior to the staplefiring).

First, portion 16 is introduced into the human or animal body and ispositioned with the jaws 21, 22 aligned at the desired stapling site toreceive the target tissue. This may involve rotation of the portion 16relative to the body, either by rotating the surgical stapler 100 as awhole, by rotating simply the portion 16 relative to the frame 12 aspermitted, or a combination of both actions. Thereafter (i.e.,secondly), the surgical stapler 100 secures the target body tissuebetween the staple cartridge or jaw 21 in the distal portion of thehousing 20 and the anvil 22. This is accomplished by a clamping actionof the jaws 21, 22 or alternatively by another similar or differentclamping member.

The jaws 21, 22 are allowed to remain in the closed position for adesired period of time depending on the particular tissue. Byconfiguring the jaws 21, 22 to remain closed for a predetermined periodof time allows any excess liquid or fluid in the tissues to drain out ofthe body tissues prior to actuation of the stapling cartridge 21. Thisensures that the liquid does not traverse out of the tissues afterfiring to form non-uniform staples and instead ensures a proper anduniform staple formation.

With the target tissue clamped between the anvil 22 and the staplecartridge 21, a camming surface which surrounds the housing 20 and anvil22 is employed to close the jaws 21, 22 of the surgical stapler 10 andclamp the tissue between the anvil 22 and the tissue contacting surfaceof the staple cartridge 21. The jaws 21, 22 are clamped by actuation ofa lever 24 opposite the jaws 21, 22 as is known in the art. Thereafter,the surgeon applies the staples to the body tissue. A longitudinallyextending channel is employed to deliver longitudinal motion to an axialdrive member and a tissue cutting knife as is known in the art.

The axial drive member or an axial drive screw contacts pusher elements.The pusher elements drive the staples through the body tissue againstthe fastener or forming surface of the anvil as discussed herein.Typically, in the art the surgical stapler 100 fires usually by anactuation of a first trigger handle or alternatively using a triggerswitch 126. Thereafter, the clamping action of the jaws 21, 22 isreleased and the surgical stapler 100 or a portion thereof may bewithdrawn from the body.

Referring now to FIG. 8, there is shown a block diagram of the surgicalstapler 100 of the present disclosure. According to a first aspect ofthe present disclosure, the surgical stapler 100 may have an optionalcontroller 128. The controller 128 is any electronic device beingcoupled to a memory for executing one or more readable programinstructions or alternatively may be a suitable analog circuit. Stillfurther, the controller 128 may be a suitable mechanical member orlinkage for controlling one or more functions of the surgical stapler100.

The controller 128 is connected to an internal or external power supplyand a motor and is connected between the anvil 22 and the staplingcartridge 21. In an alternative embodiment, a trigger handle or anotheractuating switch or component 126 is mechanically or electronicallylinked or otherwise connected to the stapling cartridge 21 as is knownin the art as indicated by a dotted line, and the present disclosure isnot intended to be limited to any configuration. Once the staplingcartridge 21 is fired using the trigger switch 126, the jaws 21, 22 areopened and the firing mechanism is retracted. The surgical stapler 100as a whole may be withdrawn from the body tissue or may be manipulatedfor a next or second stapling operation as shown.

The present surgical stapler 100 has the controller 128 which isconnected to one of the jaw or anvil 21 or jaw or staple cartridge 21and the trigger switch 126 or is connected to both jaws 21, 22 and thetrigger switch 126. In one embodiment, once the desired site is reached,the surgeon uses the jaws 21, 22 to compress the selected body tissue.Alternatively, the surgical stapler 100 may have a single drivecomponent that can actuate both the anvil 22 and stapling cartridge 21.

Thereafter, the controller 28 may provide for a requisite amount ofdelay between clamping and firing (or after clamping and before firing)to ensure tissue compression and expulsion of fluid before the staplingcartridge 21 is actuated. After the desired compression is reached, thestapling cartridge 21 may be automatically engaged by the controller 128to fire the staples from the stapling cartridge 21 into the body tissueor alternatively the controller 128 may send a signal to the surgeonthereby informing the surgeon a suggestion that the surgeon is to firethe staples. It is envisioned that the firing may be automatic ormanual.

Furthermore, the controller 128 may control the speed with which thestaples are fired from the staple cartridge 21. Still further, thecontroller 128 may control an amount of delay before firing. Thecontroller 128 in one embodiment may provide for a predetermined amountof time to elapse prior to outputting a signal to the stapling cartridge21. In another powered stapler embodiment, the controller 128 may slow amotor speed to increase the body tissue compression time.

In still another embodiment, the controller 128 may engage a dampeningdevice 130. The dampening device 130 is configured to slow the actuatingof the staple cartridge 21 in order to increase the overall compressiontime of the body tissue. Such a dampening device 130 may be a hydraulicor a pneumatic type damper or any other device that may dampen ormodulate the operation of one or more components of the surgical stapler100. In another embodiment, the trigger 126 may simply hold the firesignal for a predetermined time period in associated control circuitryand upon the expiration of the predetermined time period may communicatethe signal to the stapling cartridge 21.

The controller 128 may be configured to slow a motor speed, modulate agear or, still further, engage a circuitry of the motor to slow anoperation thereof to otherwise reduce actuation, i.e., a rotation rateof the axial drive screw. Still further, the surgical stapler 100 mayalso include an override switch 132. The override switch 132 is anautomatic or manual device (or other switch) that selectively disengagesthe controller 128 to permit direct actuation of the stapling cartridge21 by the trigger switch 126 without any delay at the surgeon'sdiscretion.

In one aspect of the present disclosure, the present surgical stapler100 includes jaws 21, 22 which compresses tissue between the anvil 170and the stapler cartridge 172 of the stapling cartridge 21 (FIG. 9B).The jaws 21, 22 are understood in the art as a device that allows thesurgeon to manipulate and compress tissue between the anvil 170 and thestaple cartridge 172 prior to urging of the staples 158 from the staplecartridge 172 as shown in FIG. 9B. The jaws 21, 22 may be independentlypowered by a power source such as a motor or pneumatic device, or may bepowered by the same power source as the staple cartridge 21. Thesurgical stapler 100 uses the jaws 21, 22 to clamp tissue between thestapler cartridge 172 and the anvil 170 (FIG. 9B), then when the stapler100 is fired the jaws 21, 22 may be further tightened and then thestaples 158 urged from the stapling cartridge 21.

In one aspect, the surgical stapler 100 may pre-clamp or compress tissueusing the jaws 21, 22 for a first interval. The first time interval maybe preset and fixed, or variable depending on the tissue type. The firsttime interval may be for minutes, seconds or any other variable or fixedpredetermined period of time. Then prior to stapling, the jaws 21, 22may further tighten to further compress the tissue for another secondcompression time interval and then fire. The second time interval may bedifferent from the first time interval and can be shorter or longer thanthe first. In another aspect, the instrument may pre-clamp or compresstissue using the jaws 21, 22 and then simply automatically fire thedevice to urge the staples 158 from the staple cartridge 132 at theconclusion of the first interval. Various configurations are possible,and the present surgical stapler 100 may have program instructions forany number of compression intervals desired by the surgeon and/ordesigner. The surgical stapler 100 may alternatively further use asecond separate clamping device in association with the stapler 100. Itis understood that the present disclosure may be incorporated into aninstrument that approximates the tissue before firing such as with a TAsurgical stapler such as U.S. Pat. No. 6,817,508 to Racenet, et al.which is herein incorporated by reference in its entirety, or can beused with an instrument that requires no such approximation beforefiring.

In another embodiment of the present disclosure, the surgical staplingdevice 100 may provide the surgeon with feedback by virtue of anindicator 136. The indicator 136 may display an amount of compressiontime and/or provide feedback of the status of the stapling, or displayinformation relating to the location of the drive screw, or drivemember. In another embodiment of the present disclosure, the surgicalstapler 100 may not have separate clamping and firing actuators andinclude a clamping gradient indicator 136 or simultaneous clamping andfiring indication mechanism. For example, the surgical stapler 100 maybe configured to allow control of the firing speed which, in turn,controls the clamping speed and timing and then provide optimalcompression for squeezing the tissue and pushing the blood and fluid outof the tissue at the desired site.

FIG. 9A shows an exploded view of a number of components of the surgicalstapler 100 of FIG. 7. The stapler 100 has a rack 101 that is slidablein the handle portion 14. The rack 101 interfaces with a clamp tube 102.On a distal side of the clamp tube 102 is a channel 104. The channel 104engages with the clamp tube 102 and a pair of forks 106, 108 on a distalside thereof. The stapler 100 also has an upper cover 110 and a lowercover 112, and an extension tube 114. The extension tube 114 engageswith a collar tube 116. The stapler 100 also has a rotation knob 118with a channel portion 120. The channel portion 120 has a pair ofcamming surfaces 122 on a distal end. The distal end also has a crimp124 in a distal side to receive the anvil portion 170 of jaw 22.

In operation, the rack 101 slides and moves the clamp tube 102 distally.The clamp tube 102 is provided to interconnect the handle portion 14 andthe extension tube 114. The channel 104 is slidably mounted forreciprocal longitudinal motion. The extension tube 114 provides supportfor the surgical stapler 100 and has slots that interface with thecollar tube 116. The surgical stapler 100 also has a support 120 forlongitudinal motion and to operate the stapling mechanism as describedin FIG. 9B. The operation of these components is well known and isdisclosed in U.S. Pat. No. 5,318,221 to Green, et al., which is hereinincorporated by reference in its entirety.

Advantageously, the rack 101 moves distally to advance the channel 104in a distal manner. The channel 104 delivers longitudinal motion to apusher cam bar as is known in the art for operation of stapler cartridge172 of jaw 21 shown in FIG. 9B. It should be appreciated that thecomponents shown in FIG. 9A only illustrate one embodiment of thepresent surgical stapler 100, and instead of the rack 101, the surgicalstapler 100 may have a drive screw (not shown) for longitudinal motionand in order to actuate the stapler cartridge 172.

Referring now to FIG. 9B, there is shown an exploded view of the jaw 22having an anvil portion 170 and the jaw 21 having a stapler cartridge172 including an actuation sled 169. The anvil portion 170 of jaw 22includes a plurality of staple deforming concavities (not shown) and acover plate 176 secured to a top surface of anvil portion 170 to definea cavity (not shown). The cover plate 176 prevents pinching of tissueduring clamping and firing of the surgical stapler 100. The cavity isdimensioned to receive a distal end of an axial drive assembly 138.

The anvil portion 170 has a longitudinal slot 140 that extends throughanvil portion 170 to facilitate passage of retention flange 142 of theaxial drive assembly 138 into the anvil slot 140. A camming surface 144formed on anvil portion 170 is positioned to engage axial drive assembly138 to facilitate clamping of tissue. A pair of pivot members 146 formedon anvil portion 170 is positioned within slots 146′ formed in carrier148 to guide the anvil portion 170 between the open and clampedpositions.

The stapler 100 has a pair of stabilizing members 152 engage arespective shoulder formed on carrier 148 to prevent anvil portion 170from sliding axially relative to staple cartridge 172 as camming surfaceof the anvil portion 170 is deformed. Cartridge assembly 172 includesthe carrier 148 which defines an elongated support channel 154.Elongated support channel 154 is dimensioned and configured to receivethe staple cartridge 172 which is shown above the carrier 148 in theexploded view of FIG. 9B. Corresponding tabs and slots formed alongstaple cartridge 172 and elongated support channel 148′ function toretain staple cartridge 172 within support channel 154 of carrier 148. Apair of support struts formed on the staple cartridge 172 are positionedto rest on side walls of carrier 148 to further stabilize staplecartridge 172 within support channel 154, however other arrangements tosupport the cartridge 172 on the channel 154 can be used and thisarrangement is not limiting.

Staple cartridge 172 includes retention slots 156 for receiving aplurality of fasteners 158 and pushers 160. Longitudinal slots 156extend through staple cartridge 172 to accommodate upstanding cam wedges162 of the actuation sled 164. A central longitudinal slot 166 extendsalong the length of staple cartridge 172 to facilitate passage of aknife blade (not shown). During operation of surgical stapler 100,actuation sled 164 is drive distally to translate through longitudinalslot 156 of staple cartridge 172 and to advance cam wedges 162 distallyand into sequential contact with pushers 160, to cause pushers 160 totranslate vertically within slots 156 and urge fasteners 158 from slots156 into the staple deforming cavities of anvil assembly portion 170 toeffect the stapling of tissue.

Referring to FIG. 10, the surgical stapler 100 may include indicator 136which may be any device known in the art to provide sensory feedback tothe surgeon. The indicator 136 may be any device that permits a visual,tactile or audible monitoring of one or more conditions of the surgicalstapler 100. The indicator 136 may be disposed on outer surface 34and/or disposed on the handle 14. Alternatively, the indicator 136 maybe disposed on portion 16 of surgical stapler 100, on the trigger switch126, on the lever 24 or in any other suitable location where theindicator 136 may be easily viewed by the surgeon without a change inposition or change in footing by the surgeon.

In one embodiment, as shown the indicator 136 includes a number of lightbulbs 238. The lights 238 may be one light or a series of many lightsbulbs or LEDs with one color or an assortment of two or more colors.Each of the lights 238 may have a color representing one or moreconditions of the surgical stapler 100. Alternatively, one or all of thelights 136 may flash to indicate a condition of the surgical stapler100.

Upon being actuated by the trigger switch 126, the surgical stapler 100may impart a delay before firing of the staples. However, in order toprovide the proper feedback to the surgeon, the lights 238 provide, forexample, a visual indication of the progress of the firing of thestapling cartridge 172. For example, still referring to FIG. 10, thereis shown a first light 240, a second light 242, a third light 244, afourth light 246, and a fifth light 248. As the axial drive screw (notshown and in the handle) travels the predetermined drive path the lights240, 242, 244, 246, and 248 illuminate in series to portray the relativedistance of the drive screw on the exterior of the handle. When thelights 240, 242, 244, 246, and 248 are illuminated, the staplingcartridge 172 fires which ensures that proper tissue compression occursprior to deployment of the staples.

Referring now to FIG. 11, in another exemplary embodiment of the presentdisclosure, the surgical stapler 100 includes a linear indicator 250having a plurality of discrete segments, first segment 252, secondsegment 254, third segment 256, fourth segment 258, and fifth segment260. Again, once the trigger switch 126 is actuated to fire the staplingcartridge 172, the segments 252, 254, 256, 258, and 260 each illuminatein a predetermined pattern to indicate to the surgeon the status of theprogression of the drive screw in the handle 14.

Upon all of the segments 252, 254, 256, 258, and 260 being illuminated,the stapling cartridge 172 fires the staple into the body tissue withassurance that an amount of compression time of the body tissue haslapsed. Linear display 250 may have one or more different colors orcombinations of colors to indicate a position of the drive screw such as“red” to indicate firing and “green” to indicate that the firing iscomplete or vice versa. Still further the linear display 250 may displayone or more graphical representations, images, or pictures to indicateone or more conditions or operating parameters of the surgical stapler100.

For example, the linear display 250 may indicate “FIRE” or “COMPLETE”,or any other graphical representation to indicate that surgical stapler100 will fire at the predetermined time period. Various possiblecombinations are possible and all are within the scope of the presentdisclosure.

In still another exemplary embodiment of the present disclosure shown inFIG. 12, the surgical stapler 100 may include a digital display 262. Thedigital display 262 may indicate a count down or count up (or other timeinterval) after actuation of the trigger switch 126. For example, thedigital display 262 may count down to the desired stapling time aftercompression to ensure a predetermined amount of tissue compression bythe jaws 21, 22. The digital display 262 may be activated by the jaws21, 22 being brought in close alignment with one another or activatedindependent of clamping. A desired clamping interval may be preset fordesired tissue.

Alternatively, the digital display 262 may be selectively preset andinput by the surgeon using an input device (not shown) or button. Thesurgeon may input a time period of clamping into the display 262.Thereafter, the display 262 will suggest firing at the elapse of theclamping time period, or may automatically fire after a predeterminedclamping time elapses (e.g., such as from about ten seconds to fortyfive seconds) to ensure proper tissue compression. The digital display262 may be configured to count down from the predetermined set intervalof clamping and visually communicate a signal to the controller 128. Thecontroller 128 after receiving the signal allows the desired time periodof clamping to elapse. After the set time period expires, the controller128 may communicate a second signal to actuate the stapling cartridge172. Alternatively, the controller 128 may simply modulate the speed ofthe motor to commence operation at a speed suitable to actuate thestapling cartridge 172 at the end of the desired time period. In stillyet another embodiment, the digital display 262 may be configured toinitiate counting after commencement of the clamping of tissue and thensimply display the time from that point onwards to allow the surgeon tomonitor and manually actuate the trigger switch 126 at the expiration ofthe desired time period. Thereafter, the digital display 262 may simplydisplay or flash the compression time to the surgeon and the exactamount of elapsed time. It is appreciated that the instrument mayprovide a predetermined delay and then indicate that the instrument isready to be manually fired, or alternatively the instrument may delaythen indicate and then automatically fire.

Referring now to FIG. 13, the surgical stapler 100 may alternativelyhave an analog display 264 disposed on the outer surface of the handle14 which functions similar to the digital display 262. Analog display264 may have an audible alarm or alternatively have a flashing light toindicate that the appropriate tissue compression time has been reachedor exceeded.

Referring now to FIG. 14, there is shown a cross sectional view of thehandle 12 of the surgical stapler along line 14-14 of FIG. 10. In thisembodiment, the surgical stapler 100 is a powered device and has a motor30 with a driving mechanism. The driving mechanism is a drive outputshaft 32. Shaft 32 connects to a first gear 68. The first gear 68 isconnected to a second gear 70 which, in turn, engages an axial drivescrew 74. The motor 30 may be a device that drives one or morecomponents of the surgical stapler 100.

The drive screw 74 is a threaded rod having a number of helical groovesthat are intended to rotate and contact another member to actuate thestapling cartridge 172 in the distal location of the surgical stapler100 once compression is made by the surgeon using the clamp or jaws 21,22. The axial drive screw 74 is disposed in toothed engagement through acentral bore 72 of the second gear 70. The axial drive screw may also bedisposed offset from the second gear 70 or in any other desired gearedarrangement. Upon actuation of the motor 30, the axial drive screw 74rotates and traverses distally through the portion 16 of the surgicalstapler 100 to engage the stapler cartridge 172 as is well known in theart. Alternatively, the surgical stapler 100 may have a drive piston orplunger instead of the axial drive screw 74 or a single drive mechanismto control both the anvil portion 170 and the stapling cartridge 172.Such mechanisms are well known in the art and may be found in U.S. Pat.No. 6,330,965 B1 to Milliman, et al., U.S. Pat. No. 6,250,532 B1 toGreen, et al., U.S. Pat. No. 6,241,139 B1 to Milliman, et al., U.S. Pat.No. 6,109,500 to Alli et al., U.S. Pat. No. 6,202,914 B1 to Geiste, etal., U.S. Pat. No. 6,032,849 to Mastri, et al. and U.S. Pat. No.5,954,259 to Viola, et al., which are all herein incorporated byreference in their entirety.

The surgical stapler 100 may include a first switch 80. Switch 80 islocated in a fixed position of the handle as shown. The stapler 100 alsohas a second switch 82 disposed distally relative to the first switch 80that is distal or near the path of the drive screw 74 in the firstinitial position 78. Likewise, the second switch 82 in a second firingposition 84 which is disposed distally from the first initial positionand proximal or near the path of the drive screw 74. Each of the firstand second switches 80, 82 is a limit switch, but alternatively may beany switch known in the art to change or toggle from a first position toa second position by a simple motion of the axial drive screw 74traversing past or adjacent to the respective limit switch.

Once the axial drive screw 74 or a portion thereof traverses past thefirst switch 80, the first switch communicates a signal to thecontroller 128 by lead 86. The controller 128 thus illuminates theindicator 136 or a portion thereof by lead 88 to indicate to the surgeona first location of the axial drive screw 74.

Thereafter, the drive screw 74 or a portion thereof traverses orcontacts the second switch 82 at the second firing position 84. Thesecond switch 82 is also a limit switch and communicates a second signalto the controller 128 by lead 90 of the location or firing of thestapler cartridge 172. The controller 128 then illuminates indicator 136(or another portion thereof) by lead 88 to indicate to the surgeon thatthe stapling has been completed. At the conclusion of the stapling, thesurgeon/operator will initiate retraction and then will reverse adirection of the motor 30 by lead 92. The motor 30 then reversesoperation and returns the axial drive screw 74 to the initial position78 for the next stapling operation.

Alternatively, controller 128 upon receiving the first signal from thefirst switch 80 by lead 86 modulates one or more operations of thesurgical stapler 100. For example, in response to receiving of the firstsignal, the controller 128 can control one or more parameters of thesurgical stapler 100 including tissue gap, speed of the motor 30,control stroke of the axial drive screw 74, axial drive screw traveldistance, rotational rate of the axial drive screw and any combinationsthereof.

Referring now to FIG. 15, the surgeon may operate/engage the firingmechanism in order to actuate the stapling cartridge 172. The firingmechanism actuates the motor 30 shown in FIG. 15. The axial drive screw74 commences rotation and by traversing past switch 80 the drive screw74 actuates the first switch 80. The first switch 80 outputs the signalto the controller 128 by lead 86. The controller 128 in response to thesignal from the first switch 80 then actuates the first light 240 bylead 92. The surgical stapler 100 may further have a suitable structurein order to engage a stop feature. The stop feature prohibits overdriveof the drive screw 74.

Thereafter, after the axial drive screw 74 traverses a predetermineddistance to ensure tissue compression by the clamp or jaws 21, 22. Thesecond switch 82 is actuated and outputs a second signal to thecontroller 128 by lead 90. The controller 128 in response to the secondsignal illuminates the second light 242 by lead 94. The second light 242indicates that the stapling cartridge 172 has fired. The second switch82 may further emit a signal to the controller 128 to reverse or ceasemotion in that direction of the motor 30 or to return the axial drivescrew 74 to the initial position. The physician/operator may alsomanually reverse the direction of the motor 30. A third light 244 mayilluminate to indicate to the surgeon that the axial drive screw 74 isreturning to the initial position 78.

FIG. 15A illustrates another embodiment of the present stapler. In theembodiment shown, the surgeon may operate/engage the firing mechanism inorder to actuate the stapling cartridge 172. However, the first switch80′ is in a different location than the embodiment shown in FIG. 15. Inthis embodiment, the first switch 80′ is located immediately under thelever 24 proximal to handle 14. The switch 80′ in the embodiment of FIG.15A engages a tab 24′ disposed on the lever 24. When the lever 24 isactuated and driven toward the handle 14, the tab 24′ contacts switch80′, and the switch 80′ outputs the signal to the controller 128 by lead86. The controller 128 in response to the signal from the first switch80 then actuates the first light 240 by lead 92.

Thereafter, after the axial drive screw 74 traverses a predetermineddistance to ensure tissue compression by the clamp or jaws 21, 22, thesecond switch 82 is actuated and outputs a second signal to thecontroller 128 by lead 90. Again, the controller 128 in response to thesecond signal illuminates the second light 242 by lead 94. The secondlight 242 indicates that the stapling cartridge 172 has fired. Thesecond switch 82 that is actuated by switch 80′ may further emit asignal to the controller 128 to reverse or cease motion in thatdirection of the motor 30 or to return the axial drive screw 74 to theinitial position. A third indicator 244 may be included to indicate tothe surgeon that the axial drive screw 74 is returning to the initialposition 78.

FIG. 15B shows still another embodiment wherein the first switch 80″ islocated at still another location of the handle 14, and on an oppositedistal side of the lever 24 in proximity to pivot. Variousconfigurations are possible and within the scope of the presentdisclosure, and switch 80″ may be placed in various configurationsrelative to the lever 24.

FIG. 16 shows the surgical stapler 100 with a lever 24. The lever 24,shown in the elevated position, controls the clamp of jaws 21, 22,however this arrangement is not limiting and another driving member maycontrol the clamp of jaws 21, 22 such as the motor 30 (FIG. 14). Thelever 24 opens and closes the jaws 21, 22 of the clamp to compress thebody tissue prior to surgical stapling. The surgical stapler 100 furtherincludes an electrical contact 96 with an electrically conductive memberto complete a suitable analog or digital circuit. The electrical contact96 is in a complementary nesting location of the lever 24 when the leveris in a lowered position or mating with the handle 14. When the lever 24is lowered from an elevated or raised position to the lowered positionor contacting the handle 14, the lever 24 engages the electrical contact96. The electrical contact may complete a suitable timer circuit of thedisplay 262 when in the lowered position. In this embodiment, theelectrical contact 96 commences the display 262. The display 262 maycount upwards from zero to a predetermined time limit, or may count downfrom an ideal predetermined tissue compression time interval. Once thedisplayed time reaches the predetermined time interval, an audible alarm98 may sound. The audible alarm 98 provides the surgeon with a cue thatthe optimal tissue compression time has been reached, and that thefiring mechanism should be actuated in order to fire the staple from thestaple cartridge 172 to ensure a uniform staple formation.

FIG. 17 illustrates in still another embodiment where the clamp formedby jaws 21, 22 is actuated by lowering the lever 24. Contemporaneously,the timer circuit of the display 262 is activated by the electricalcontact 96 on the lever 24. The indicator 36 may be the linear display250 which indicates a first color to prompt for the actuation of thestaple cartridge 172 by the trigger switch or button 126. The display250 may then display a second image or illuminate the number of segmentscorresponding to a travel path of the axial drive screw 74 as shown inFIG. 14. Upon actuation, the second switch 82 outputs a signal to thecontroller 128. The controller 128 then stops the motor 30, and thecontroller outputs a control signal to the display 250 to modulate thedisplay from the first color to another second color or from a firstimage to a second image to indicate that the staple cartridge 172 hasfired. Optionally, the controller 128 may further sound the audiblealarm 98 indicating that the staple cartridge 172 has fired. The alarmmay be any sound or audible pattern, including a buzzer, a song, achirp, a chime or any combinations thereof. Various indicatorconfigurations are possible and within the scope of the presentdisclosure.

In still another embodiment, the jaws 21, 22 may be actuated by loweringthe lever 24. Contemporaneously, the timer circuit of the display 262 isactivated by the lever 24. Thereafter, the indicator 136 indicates afirst indication to prompt for an actuation of the staple cartridge 172by actuating switch 126 after a desired time period elapses. Once thetrigger switch 126 is actuated, the controller 128 activates the motor30. The motor 30 then moves the drive screw 74 as shown in FIG. 14.

As the axial drive screw 74 moves in an axial manner, the drive screw(or another plunger 101 connected thereto as shown in FIG. 18, contactsa second member 102. Second member 102 may be any member that modulatesbased on the motion of the plunger 101 and that can be detected orsensed by another device to provide an indication to the surgeon. Thesecond member 102 may be a resistor strip which changes a resistancealong a travel surface 104 of the plunger 101 as the plunger 101 or theaxial drive screw 74 traverses along the portion 16 of the surgicalstapler 100 (or other suitable travel surface location). The resistorstrip 102 is coupled to indicator 136 such that the change in resistanceof the resistor strip 102 selectively illuminates each of the lights 240through 248 to signal an amount of travel by the axial drive screw 74 orthe plunger 101 or other suitable drive member.

Alternatively, the resistor strip 102 may be coupled to anotherindicator 136 such as a linear display 250. The display 250 mayilluminate the number of segments 252, 254, 256, 258, and 260corresponding to a travel of the axial drive screw 74 or the plunger 101until the axial drive screw actuates the staple cartridge 172. Uponactuated, the resistor strip 102 outputs a signal to the controller 128which modulates the operation of the motor 30, and sends another secondsignal to the display 250 to indicate that the staple cartridge 172 hasfired. The display 250 in response thereto may then display a suitablegraphical image, another color, a textual message, or any otherindication to indicate to the surgeon that the firing of the staplecartridge 172 has concluded. Various indicator configurations arepossible and within the scope of the present disclosure.

Referring now to FIG. 19, in yet another embodiment of the presentdisclosure, the surgical stapler 100 may further include a non-contactsensor 106. The non-contact sensor 106 may optionally be a so-called“Hall effect non-contact sensor” (or alternatively any other non-contactsensor) that is based in part on the physical principle of the Halleffect named after its discoverer E. H. Hall.

For example, end 108 of the axial screw 74 is directly connected, gearedto, or offset from the motor 30, and a cap like free end 110 of axialscrew 74 contacts the staple cartridge 172 to actuate the staplercartridge and to fire the staple as discussed previously. The free end110 of the drive screw 74 has a magnetic member 112 which connectsthereto and which will not become dislodged by a rotation of the drivescrew 74. Alternatively, the magnetic member 112 may be disc shaped andsimply connect to the free end 110. In one initial orientation, free end110 and the magnetic member 112 are disposed closely adjacent, or nearto the non-contact sensor 106. At this initial orientation, the magneticmember 112 is separated by a first distance “d” from the non-contactsensor 106.

Once the trigger switch or button 126 is actuated, the motor 30 isactuated, and rotates, the drive axial screw 74 to traverse distally toactuate the staple cartridge 172 as described above. In the secondorientation after the motor 30 has been actuated, the magnetic member112 moves and is a second distance “d” away from the non-contact sensor106. The second distance is any distance greater than the first distance“d”. As the magnetic member 112 moves away from the non-contact sensor106, the non-contact sensor now located the second distance away fromthe magnetic field of the magnetic member 112 modulates an operation ofthe motor 30.

The term “modulation” is defined as modulating amount of voltagereceived by the motor 30 in a dynamic manner, turning the motor “off” ata desired stroke, changing the motor speed, drive gear reduction of themotor, reduction of the axial drive screw pitch, or a change in thevoltage or the current input of the motor, or changing another firingcomponent, a change of the motor components and any combinationsthereof. This may thereby slow the operation of the motor 30 to increasean amount of compression time of the body tissues between jaws 21, 22.In another alternative embodiment, the magnetic member 112 may bedisposed on a suitable drive piston instead of the drive screw 74. Asthe drive piston travels away from the non-contact sensor 106, a reducedor modulated amount of voltage may be provided to the motor 30. Stillfurther in another alternative embodiment, the non-contact sensor 106may be placed at the free end 110 of the drive screw 74 and the magneticmember 112 fixed.

In another embodiment of the present disclosure, the surgical staplermay have a combined drive mechanism. The combined drive mechanism maycontrol both a firing component of the stapling mechanism and a clampingmechanism. The surgical stapler 100 may, upon being actuated, has thedrive mechanism advance to commence the clamping using the clampingmechanism and then hold and wait thus providing a predetermined delay.The surgical stapler 100 would then provide an indication to thesurgeon/operator once a desired amount of compression is reached.Thereafter, the surgeon/operator would then actuate the drive mechanismafter the time delay. The drive mechanism would then fire the staplesfrom the staple cartridge 172 into the compressed tissues and thusensure a uniform staple formation. The surgical stapler 100 thusprovides a time delay prior to stapling to ensure tissue compression.

Although shown as an endoscopic surgical stapler, the present drivesystem may be used with any surgical stapling device known in the art,such as endoscopic surgical stapling devices, a multi-fire GIA surgicalstapler, a TA surgical stapling device, and/or any other surgicalstapler device known in the art. The present instrument may also be usedwith a single drive surgical stapler that drives both the clampingdevice of the jaws 21, 22 and the stapling device.

It should be understood that the foregoing description is onlyillustrative of the present disclosure. Various alternatives andmodifications can be devised by those skilled in the art withoutdeparting from the disclosure. Accordingly, the present disclosure isintended to embrace all such alternatives, modifications and variances.The embodiments described with reference to the attached drawing figuresare presented only to demonstrate certain examples of the disclosure.

Other elements, steps, methods and techniques that are insubstantiallydifferent from those described above and/or in the appended claims arealso intended to be within the scope of the disclosure.

1. (canceled)
 2. A powered endoscopic surgical apparatus, comprising: anendoscopic portion; an end effector assembly coupled to a distal endportion of the endoscopic portion, the end effector assembly including apair of jaws configured to perform a surgical function, at least one ofthe jaws being movable with respect to the other jaw; a handle coupledto a proximal end portion of the endoscopic portion, the handleincluding: a housing; a power source supported in the housing; a closinglever supported on the housing; and a closure member having a proximalend portion operatively connected to the closing lever and a distal endportion extending through the endoscopic portion to the end effectorassembly, wherein manual actuation of the closing lever imparts linearmovement of the closure member such that the distal end portion of theclosure member engages and actuates the end effector assembly to openand close the pair of jaws; a driving member extending between thehandle and the end effector assembly, the driving member configured totranslate along a drive path thereof to selectively actuate the endeffector assembly; a motor powered by the power source and connected tothe driving member such that the driving member is translated along thedrive path upon actuation of the motor; a sensor disposed along thedrive path of the driving member; and a controller operatively coupledto the sensor and the motor, the controller configured to modulate themotor upon receiving a first signal from the sensor corresponding to thelocation of the driving member along the drive path.
 3. The poweredendoscopic surgical apparatus according to claim 2, wherein the sensorincludes a resistor strip coupled to a travel surface of the drive path,wherein the first signal is a change in resistance detected by theresistor strip as the driving member translates along the travel surfaceof the drive path.
 4. The powered endoscopic surgical apparatusaccording to claim 3, wherein the change in resistance detected by theresistor strip corresponds to a change in the location of the drivingmember along the travel surface of the drive path.
 5. The poweredendoscopic surgical apparatus according to claim 2, wherein the sensoris a non-contact sensor located along the drive path, the non-contactsensor operatively coupled to a portion of the driving member todetermine a distance between the non-contact sensor and the portion ofthe driving member.
 6. The powered endoscopic surgical apparatusaccording to claim 5, wherein in an initial orientation of the drivingmember, the non-contact sensor is disposed adjacent the portion of thedriving member and spaced apart a first distance from the portion of thedriving member.
 7. The powered endoscopic surgical apparatus accordingto claim 6, wherein upon translation of the driving member along thedrive path, the non-contact sensor is spaced apart from the portion ofthe driving member a second distance greater than the first distance ofthe initial orientation of the driving member and the non-contact sensortransmits the second signal to the controller to modulate the motor. 8.The powered endoscopic surgical apparatus according to claim 7, whereinthe non-contact sensor includes a hall effect sensor and the portion ofthe driving member includes a magnetic member, the hall effect sensorconfigured to determine a change in a magnetic field of the magneticmember from the first distance between the hall effect sensor and themagnetic member to the second distance between the hall effect sensorand the magnetic member.
 9. The powered endoscopic surgical apparatusaccording to claim 8, wherein the magnetic member is disposed on adistal portion of the driving member.
 10. The powered endoscopicsurgical apparatus according to claim 7, further comprising: a graphicaldisplay supported in the housing and operatively coupled to the sensor,the graphical display configured to receive a first signal from thesensor corresponding to a location of the driving member along the drivepath and display a visual indication corresponding to the location ofthe driving member along the drive path.
 11. The powered endoscopicsurgical apparatus according to claim 10, wherein the graphical displayincludes a series of discreet segments, each discreet segment of theseries of discreet segments configured to illuminate in succession toindicate a travel distance of the driving member along the drive pathuntil the end effector assembly is actuated.
 12. The powered endoscopicsurgical apparatus according to claim 11, wherein the controller isoperatively coupled to the graphical display such that upon actuation ofthe end effector assembly, the graphical display is configured toreceive a third signal from the controller and transmit the visualindication that the end effector assembly has been fired.
 13. Thepowered endoscopic surgical apparatus according to claim 12, wherein theclosing lever includes an electrical contact configured to send a fourthsignal to the graphical display upon manual actuation of the closinglever.
 14. The powered endoscopic surgical apparatus according to claim2, wherein the power source is a battery.
 15. The powered endoscopicsurgical apparatus according to claim 2, wherein the end effectorassembly is a stapling mechanism.
 16. The powered endoscopic surgicalapparatus according to claim 15, wherein translation of the drivingmember actuates the end effector assembly to perform a staplingfunction.